Note: Descriptions are shown in the official language in which they were submitted.
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PATENT
TAMPON HAVING A LIQUID-PERMEABLE COVER
Field of the Invention
This invention relates to an apparatus and a method for more
efficiently forming tampons and also to tampons formed by this
method. `
Backaround of the Invention
Currently, there are two basic types of tampons used for
feminine hygiene. The first type is a digitally insertable tampon
which is designed to be inserted directly by the user's fingers. The
second type is an applicator style tampon which is designed to be
inserted with the aid of an applicator. Both types are usually made
by folding or rolling a loosely associated rectangular strip of
absorbent material into a blank and then compress1ng the blank into a
cylindrically shaped product known as a pledget. The pledget may or
may not have a cover, depending upon the manufacturer. In both
types, a withdrawal string is attached to the pledget before the
tampon is wrapped and packaged for sale. In the applicator style
tampon, the tampons are assembled into an applicator prior to being
wrapped and packaged.
Up until now, tampons have been normally manufactured in either
an in-line process or in an intermittent indexing type operation.
Some representative methods of forming tampons and the apparatuses
associated with these methods are disclosed in U.S. patents
4,816,100; 4,Ç24,668; 4,6429108; and 6erman patent DE 3,347,649.
Most current processes operate at speeds which are considered
slow by today's standards. With the increase in labor costs and
competition, it is necessary for manufacturers to be able to
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significantly increase the speed at which tampons can be made. It is
also beneficial if manufacturers can utilize a major portion of their
existing machinery while increasing the process speed.
Since most tampon manufactures have not even considered cutting
an elongated pledget into two or more single length pledgets, there
is very little prior art. However, in U.S. patent 4,755,164 a method
is disclosed for forming hollow applicator tubes by cutting the tubes
in half. An applicator tube is different frum a tampon in that it is
usually constructed of thick paper or plastic, is not designed to
remain in a woman's vagina, and does not contain a fibrous core. Two
other patents which relate to slic;ng an article in half include U.S.
patent 271,625 and Canadian patent 614,475. In both of these
patents, only the outer cover of a tampon is sliced in half while the
fibrous core is left uncut.
German patent 3,347,649, cited above, teaches a tampon wherein
the cover strip is narrower than the width of the absorbent. This
patent also shows, in Figure 6, a tampon wherein the insertion end is
uncovered by the cover strip while the retrieval end has the cover
strip positioned tangent to it.
Now an apparatus and a method have been developed which can
' produce unique tampons quickly, efficiently and at a cheaper cost. `~
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Summarv of the Invention
Briefly, the present invention relates to an apparatus and a
method for forming tampons and to the tampon itself. The apparatus
includes a mechanism for advancing and individually cutting a cover
strip and an absorbent ribbon into defined lengths. An individual
length of cover strip is then overlapped onto a portion of an
individual length of absorbent ribbon and is attached thereto such as
by heat and/or pressure. Both strips are then rolled into a cylinder
with the cover strip encircling the outer circumference thereof. The
cylinder is compressed into an elongated pledget and is then cut into
at least two single length pledgets. The apparatus further includes
a heat setting device and a means for attaching a withdrawal string
approximate one end of the tampon.
The method includes the steps of positioning a liquid-permeable
cover strip over a portion of a nonwoven absorbent ribbon, both of
; which have a defined length and width. The cover strip is attached
to the ribbon at the overlapped portion and both are rolled into a
cylinder with the cover strip encircling the outer circumference
thereof. The cylinder will have a length corresponding to the length
of at least two finished tampons. The elongated cylinder is
compressed into a pledget which is then cut into at least two single
length pledgets. Each single length pledget is heat set to a desired
configuration before having a withdrawal string attached thereto.
The finished pledget can be wrapped or assembled into an applicator '
~! 25 before being shipped to the ultimate consumer.
The tampon comprises a radially wound nonwoven absorbent ribbon
circumferentially surrounded by a liquid-permeable cover strip. Both
the ribbon and cover strip are compressed into a cylindrical shape
having first and second oppositely aligned ends wherein the ribbon is
exposed on either one or both ends. The absorbent ribbon is sized
relative to the cover strip such that finished tampons can be
manufactured with tucked or untucked ends, or with a cylindrical cuff
if desired.
The general object of this invention is to provide an apparatus
and a method for continuously forming tampons. A more specific
object of this invention is to provide an apparatus and a method for
forming two or more tampons from a single elongated pledget.
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Another object of this invention is to provide an apparatus and
a method for forming multiple tampons at a high rate of speed, more
efficiently and at a lower cost compared to present day processes.
Still, another object of this invention is to provide a tampon
having a unique configuration wherein one or both ends exhibits
exposed absorbent ribbon.
Still further, an object of this invention is to provide a
tampon wherein one end can be covered by having the cover strip
tucked into the absorbent ribbon.
Other objects and advantages of the present invention will
become more apparent to those skilled in the art in view of the
following description and the accompanying drawings.
Brief Description of the Drawings
Figure 1 is a schematic view of an apparatus for forming tampons
at high speeds.
Figure 2 is a top view of a pair of heat set wheels having a
cutter positioned therebetween.
Figure 3 is a side view of the pair of heat set wheels showing a
stop mechanism, a centering mechanism and the cutter position
therebetween.
Figure 4 is a perspective view of a softwind, double length
cylinder showing a large opening formed through the absorbent and
showing the cover strip as having an unattached tail portion.
Figure 5 is a perspective view of a compressed, elongated
pledget having a hexagonal shape.
Figure 6 is a perspective view of two single length pledgets
which have undergone heat set and have acquired a circular cross-
sectional shape.
Figure 7 is a side view of a finished tampon showing an aperture
diametrically formed therethrough and having a withdrawal string
inserted therethrough and looped about itself so as to form a secured
attachment.
Figure 8 is a perspective view of a tampon produced according to
this invention and assembled into a tampon applicator.
Figure 9 is a schematic view of a stick tampon packaged in a
thermoplastic pouch.
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Figure 10 is a perspective view of a softwind wherein the cover
- strip has a longer width than the absorbent ribbon so that it can be
tucked into one or both ends of the absorbent ribbon to form a
covered tampon.
Figure 11 is a perspective view of an elongated pledget having
the cover tucked into both ends of the radially wound absorbent
ribbon.
Figure 12 is a perspective view of a compressed elongated
pledget formed from the softwind shown in Figure 11.
Figure 13 is a perspective view of two single length pledgets
each having a tucked end and an untucked end.
Figure 14 is a side view of a pledget having a rounded insertion
end and having a withdrawal string secured to the trailing end.
Figure 15 is a side view of a pledget showing a rounded
insertion end exhibiting exposed absorbent ribbon and a trailing end
` which is completely covered.
Figure 16 is a perspective view of a radially wound absorbent
ribbon showing a cover having an initial width which is less than the
initial width of the absorbent ribbon such that it does not extend to
^~i 20 either end of the absorbent ribbon.
;~ Figure 17 is a perspective view of a compressed hexagonal shaped
.,
~, pledget made from the radially wound softwind shown in Figure 16.Figure 18 is a perspective view cf two single length pledgets
~ showing the cover surrounding the outer circumference of the
,~ 25 absorbent ribbon and being spaced apart from the insertion end and
being-aligned even with the trailing end.
~1 Figure 19 is a side view of a pledget having a rounded insertion
end with the cover strip spaced away from this end to form a cuff.
Figure 20 is a top view of an absorbent ribbon partially
'i 30 overlying one end of a cover strip and having a length and width
J equal to the length and width of the cover strip.
Figure 21 is a top view of an absorbent ribbon partially
! overlying one end of a cover strip and having a length equal to the
length of the cover strip and having a width less than the width of
ii 35 the cover strip. ~ ;
j Figure 22 is a perspective view of a radially wound absorbentribbon showing a cover strip having a width greater than the width of
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the absorbent ribbon such that the cover strip forms a sleeve on one
end of the radially wound absorbent ribbon.
Figure 23 is a top view of an absorbent ribbon partially
overlapping one end of a cover strip and having a length equal to the
length of the cover strip and having a width less than the width of
the cover strip.
Figure 24 is a top view of an absorbent ribbon partially
` overlapping one end of a cover strip and having a length and width
greater than the length and width of the cover strip.
Figure 25 is a top view of an absorbent ribbon partially
overlapping one end of a cover strip and having a length less than
the length of the cover strip and having a width equal to the width
of the cover strip.
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Detailed Description of the Preferred Embodiments
Referring to Figure 1, an apparatus lO is shown for continuously
forming tampons at high speeds and in an efficient manner. The
apparatus 10 includes a set of rollers 12 which grasp and advance a
continuous supply of absorbent ribbon 14. The absorbent ribbon 14
can be any suitable absorbent material made from artificial or
natural fibers including polyester, cellulose, acetate, nylon,
polypropylene, rayon, cotton or blends thereof. The absorbent ribbon
14 can also be a nonwoven, bonded carded web comprised of between
about 70 and 95% rayon and about 5 to 30% cotton. Normally, the
fibers are formed by convolutely winding multiple fibers into a
ribbon form. The absorbent ribbon 14 can have a width of one or more
inches (about 25 or more millimeters) but, when two pledgets are to
be formed from a single width, the width should preferably be between
4 and 6 inches ( about 100 to l50 millimeters). The absorbent
ribbon 14 should have two longitudinal side edges 15 and 17 which are
2i approximately parallel to one another.
The absorbent ribbon 14 is directed through a second set of
rollers 16 which continuously rotate. The first set of rollers 12
can be programmed to stop and start at certain intervals such that
the action between the two sets of rollers 12 and 16 will cause the
ribbon 14 to tear into a defined length. The length of the ribbon 14
will vary depending upon the desired weight and/or diameter of the -
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finished tampon. However, for most applications, a length of between
6 to 12 inches( about 150 to 300 millimeters), and preferably around
9 to 11 inches ( about 225 to 275 millimeters) is satisfactory. The
cut ribbon 14 should have a generally rectangular configuration.
The apparatus 10 also contains a set of rollers 18 which can
grasp and advance a continuous supply of a cover strip 20. The cover
strip 20 can be constructed of natural or synthetic materials which
are preferably liquid permeable. The cover strip 20 can be a powder
bonded carded web made from 0 - 100% rayon, 0 - 100% polyester,
0 - 100% cotton or it can be made of another type of polymer, or a
blend thereof. The cover strip 20 could also be made from
cottonwool. A particular useful blend for the base material is about
85% polyester and about 15% rayon. A binder is usually added to the
base material to give the cover strip 20 adhesion properties so that
` 15 it will bond to the absorbent ribbon 14 as well as to itself at theoverlap areas. A particularly useful powder binder is about 10 - 25% -:
polyester powder, preferably about 15 - 20~o. The powder binder can
be obtained from Bonar Fabric~ Corporation, 50 Arcadia Drive, P. 0.
Box 3745, Greenville, South Carolina, 29608.
After passing between the rollers 18, the cover strip 20 is
routed between the nip of a pair guide rollers 22 and then past a
,3 pair of feed rolls 24. The feed rolls 24 direct the cover strip 20onto a transfer roll 26 which contàins a pair of anvils 28 arranged
on it's inner circumference. A cutter roll 30 is positioned adjacent
to the outer periphery of the transfer roll 26 and downstream of the
feed rolls 24. The cutter roll 30 is synchronized so as to line up
with the anvils 28 and will cut the cover strip 20 into generally
rectangular segments having approximately parallel longitudinal side
3' edges. The cover strip 20 will have a defined length, preferably
between 5 and 8 inches ( about 125 to 200 millimeters). The width of
the cover strip 20 can be varied so as to be longer, shorter or equal
to the width of the absorbent ribbon 14. The particular width of the
cover strip 20 will impact upon the final configuration of the
finished tampon.
The cover strip 20 can be dimensioned to have a longer length
than the absorbent ribbon. For example, the cover strip can be sized
between about 5 to 12 inches (about 125 to about 300 mm.),
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preferably, about 9 to 12 inches (about 225 to about 275 mm.). In
some instances, it may be advantageous to cut the cover strip 20 to
approximately the same length and/or width as the absorbent ribbon
* 14.
In Figure 20, the absorbent ribbon 14 has a length 'ILl'' and a
width "W~" which is equal to the length "L~" and the width "W~",
respectively, of the cover strip 20. In Figure 21, the length
"L2"of the cover strip 20 is less than the length "L~" of the
` absorbent ribbon 14, while the width "W2" of the cover strip 20 is
greater than the width "W~" of the absorbent ribbon 14. The
; construction of the absorbent ribbon 14 and the cover strip 20 can
; produce the tampon shown in Figure 22 wherein a sleeve 160 is formed
- at the insertion end of the tampon.
In Figure 23, the absorbent ribbon 14 has a length "L~" equal to
the length "L~" of the cover strip 20 and a width "W~" less than the
width "W2" of the cover strip 20. In Figure 24, the absorbent
article 14 has a length "L~" greater than the length ~IL2~ of the
cover strip 20 and has a width "W1" greater than the width "W3" of
the cover strip 20. Lastly, in Figure 25, the absorbent article 14
has a length "L2" smaller than the length "L1" of the cover strip 20
i and has a width "W~" equal to the width ~W1" of the cover strip 20.
The individual lengths of the cover strips 20 can be held onto
, the outer circumference of the transfer roll 26 by vacuum. The
transfer roll 26 is rotated clockwise and will contact a continuous
$ 25 belt 32 which is used to transport individual segments 34 of the
absorbent ribbon 14. Preferably, the individual segments 34 have a
basis weight of at least 100 grams per square meter. As the
individual segments 34 pass under the transfer roll 26, the speed of
the transfer roll 26 can be adjusted such that a portion of an
individual cover strip 20 will overlap a portion of the individual
absorbent segment 34. At this point, the vacuum is turned off and
the cover strip 20 will separate from the transfer roll 26. The
combination absorbent ribbon and cover strip, denoted 36, is passed
between the nip of a heated roll 38 and an anvil roll 40. The heated
roll 38 can have a knurled or tooth shaped pattern formed on a
¦ portion of it's periphery so as to impinge upon the cover strip 20
~ and press it against the surface of the absorbent ribbon 14. The use
of heat and/or pressure will cause the cover strip 20 to bond to the
absorbent ribbon 14. The heat will activate the binder which is
present within the cover strip 20 to assure that a secure bond is
formed. However, it is possible to bond the cover strip 20 to the
absorbent ribbon 14 by using just pressure, such as by passing the
combination 36 between a pin roll and an apertured roll. Likewise,
the combination 36 could be bonded together by just using heat or by
using other types of bonding such as ultrasonic energy, laser beam,
etc.
The particular area over which the cover strip 20 overlaps the
absorbent ribbon 14 will depend upon the preFerence of individual
manufacturers. It should be noted, however, that a smaller
overlapped area may means that the equipment must be synchronized
more precisely. It should also be noted that the heated roll 38,
with its knurled or tooth profile, can first contact the absorbent
ribbon 14 before engaging the cover strip 20, if this is desireable.
Likewise, it is also possible to construct the heated roll 38 such
that it will bond only a portion of the overlapped cover strip 20 to
the absorbent ribbon 14, instead of bonding over the entire length
and/or width of the overlapped section.
; The absorbent ribbon 14 with its bonded cover strip 20 is
advanced by the continuous belt 32 and is brought into contact with a
first turret 42. The first turret 42 contains a plurality of
mandrels 44 arranged in a circle which can individually rotate. The
first turret 42 is driven by a mechanism which will permit it to
index a predetermined amount as it rotates through each complete
revolution. For purposes of illustration, the first 42 turret is
shown as rotating counterclockwise. Each mandrel 44 has a plurality
of small ports formed in it's outer periphery which communicate with
a source of vacuum so as to provide a means for grasping the end of
the absorbent ribbon 14. The ribbon 14 is radially wound into a
cylinder 46, see Figure 4, which is commonly referred to as a
"softwind". The cylinder 46 has oppositely aligned ends 49 and 51.
The diameter of the softwind cylinder 46 should be less than the
opening of the mold cavity into which it is to be inserted. Typical
diameters for the cylinder 46 is about 1 to 2 inches ( about 25 to 50
millimeters) and the diameter of the hollow opening formed therein
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is about 3/4 to 1 ;nch ( about 18 to 25 millimeters). A good
illustration of a softwind is shown in Figures 4? 8 and 14.
In situations where the width of the cover strip 20 is
approximately equal to or less than the width of the absorbent
ribbon 14, there is no need for a tucking operation. However9 when
the cover strip 20 has a width larger than the width of the absorbent
ribbon 14, as is depicted in Figure 8, then a tucking operation is
required. The tucking operation will fold the sleeve portion of the
cover strip 20, which extends beyond each end of the absorbent
ribbon 14, into the hollow opening of the cylindrical softwind 46.
~ The first tucking operation, when needed, will occur when the
`~ softwind 46 is positioned on the mandrel 44. Each mandrel 44
contains a central passageway which terminates at a distal outer end.
Once the cylinder 46 is wound onto the mandrel 44, a vacuum is
applied through the passageway to pull the sleeve portion of the
cover strip 20 into a central opening 47 formed in the softwind 46
; and tuck it, thereby covering the absorbent ribbon 14. Each
cylinder 46 is then transferred from the first turret 42 to a second
turret 48 while both turrets are momentarily stopped. The second
turret 48 is designed to rotate in an indexing fashion just like the
first turret 42 and also contains a plurality of mandrels 50. Each
of the mandrels 50 has a central passageway which terminates into an
exposed port located in the outer end thereof which communicates with
a source of vacuum. As the second turret 48 is indexed to a desired
pusition, a vacuum will be applied to pull the sleeve portion of the
cover strip 20 into the opposite end of the softwind 46 and tuck it
into the opening formed therein. In this fashion, both ends of the
; cover strip 20 can be tucked into the softwind 46.
It should be noted that the diameter of each of the mandrels 50
will be slightly smaller than the diameter of the opening 47 formed
in the cylindrical softwind 46. This size difference is beneficial
for it prevents the first tuck from being destroyed as the
softwind 46 is transferred to the mandrel 50.
As depicted in Figure 1, the second turret 48 will rotate
counterclockwise in an indexing fashion such that each of the
mandrels 50 will come into alignment with a compressor 52. The
compressor 52 contains a mold cavity 54 which will sequentially
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receive the softwinds 46 as they are transferred from the
mandrels 50. One ~eans of ejecting the softwinds 46 from the second
mandrel 50 is to use a push-off spool 56 which is coaxially aligned
and moveable with respect to each mandrel 50. The push-off spools 56
can be mechanically, electrically, pneumatically or hydraulically
activated so as to transfer the softwind 46 into the mold cavity 54.
The compressor 52 operates in a unique fashion, as is explained in
U.S. serial number 07/383,129 filed July 20, 1989, and entitled
"Apparatus For Compressing Materials". This U.S. patent application
is cnmmonly assigned and is incorporated by reference and made a part
hereof.
In general, the compressor 52 includes a plurality of dies 58
which reciprocate relative to one another so as to form the mold
cavity 54 therebetween. When the softwind 46 is positioned within .
;15 the mold cavity 54, the front and back gates of the compressor 52
will be closed thereby forming a closed cavity. The dies 58 will
then be actuated so as to move towards one another and compress the
~softwind 46. The softwind 46 can be compressed a desired amount, for
-example at least 25%, preferably in the range of 50 to 20~/o~ and most
;20 preferably in a range of about 100 to lSOYo of the initial diameter of
the softwind 46. The compression will cause the softwind to be
reduced in diameter to a fraction of it's original diameter, for
example to approximately 1/4 of its original diameter. In the
formation of tampons, the compressed material, which is known as a
pledget, will usually have a diameter of less than 1/2 of an inch
(about 12 millimeters).
Referring to Figure 5, a good representation of an elongated
pledget 60 is shown. The elongated pledget 60 is shown having a
hexagonal configuration which is formed by a compressor containing
six dies 58 arranged in a circular fashion and positioned
'approximately 60 apart. However, the cross-sectional configuration
of the elongated pledget 60 can vary depending upon the number of
dies 58 being used in the compressor 52 and the surface shape of each
of the dies 58. For example, a triangular cross-sectional
configuration could be formed by using three dies or a square cross-
sectional configuration could be obtained by using four dies. If the
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dies 58 had concave surfaces, a circular cross-sectional
configuration could be obtained.
Referring again to Figs. 1-3, when the rear gate on the
compressor 52 is opened, the elongated pledget 60 is released and is
directed by vacuum or air through a feed tube 62 towards a pair of
`~heat set wheels 64 and 66. The heat set wheels 64 and 66 are
rotatably mounted on individual shafts 68 and 70, respectively, and
are angularly offset from one another. The heat set wheels 64 and 66
are essentially identical in construction and each contains a
plurality of apertures 72 spaced about the outer circumference
thereof. Each of the apertures 72 has a diameter which is larger
than the diameter of the compressed pledgets 60. The heat set
wheels 64 and 66 are designed to be elevated in temperature to a
desired value for at least a portion of the 360 cycle so as to heat
set the configuration of the pledgets. The temperature can be
adjusted between room temperature and about 250-F. Depending upon
operational preferences, the apertures 72 into which the elongated
pledget 60 is first received can be preheated or alternatively, the
apertures 72 can be heated at a later time during the 360 degree
rotational cycle of each of the heat set wheels 64 and 66. The heat
set wheels 64 and 66 are rotated in an indexing fashion and, at a
given indexed position, one of the apertures 72 formed in the first ~`
heat set wheel 64 will be coaxially aligned with one of the
apertures 72 formed in the second heat set wheel 66. In addition,
the two coaxially aligned apertures 72 will be axially aligned with
the feed tube 62 and be connected thereto.
As best shown in Figures 2 and 3, each elongated pledget 60 will
be fed into the axially aligned apertures 72 formed in both the first
and second heat set wheels 64 and 66 and will come to rest against a
stop 74. The stop 74 is positioned adjacent to the outside surface
of the second heat set wheel 66. When the elongated pledget 60 comes
to a stop, it will be positioned across the width of both the first
and second heat set wheels 64 and 66. The heat set wheels 64 and 66
are then indexed (rotated a predetermined amount) and the elongated
~35 pledget 60 is brought into alignment with a centering device 76. The
{~centering device 76 contains a pair of fingers 78 and 80, each
positioned against the outer surface of the heat set wheels 64
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and 66, respectively. The fingers 78 and 80 are connected to a
source of pressurized air 82 and are pneumatically actuated, such as
by air cylinders. It should be noted that other mechanical,
electromechanical, hydraulic or pneumatical devices can be utilized
as a centering device. The centering device 76 operates by
; simultaneously moving the fingers 78 and 80 inward a set distance
towards the elongated pledget 60. This causes the elongated
pledget 60 to be centered between the two heat set wheels 64 and 66.
The two heat set wheels 64 and 66 are then indexed (rotated a
predetermined amount) and the elongated pledget 60 is brought into
engagement with a cutter 84. The cutter 84 is positioned between the
two heat set wheels 64 and 66 and contains a blade ~6 which can be
rotated in either a clockwise or counter clockwise direction. It
should be noted that the cutter 84 can be a conventional cutter, such
as a bandsaw or a rotary blade. The cutter 84 can also have one or
more rotary blades or movable knifes. Furthermore, a laser, a water
jet or an ultrasonic energy device could also be used. The cutter 84
is capable of cutting the elongated pledget 60 into two equal, single
length pledgets 88 and 90, as shown in Fig 6. By "single length" is
meant a length approximately equal to the length of the finished
tampon. In situations where the elongated pledget 60 is designed to
be cut into three or more parts, it is possible to position cutters
between several heat set wheels. For example, if one wished to cut
an elongated pledget 60 into three parts, one would use three heat
set wheels with a cutter positioned between each pair of wheels.
Each of the two single length pledgets 88 and 90 will remain in
it's respective opening 72 formed in each of the heat set wheels 64
and 66 and will be exposed to a heating operation as the heat set
wheels 64 and 66 are rotated. The pledgets 88 and 90 can be heated
prior to being cut, after being cut or while being cut if desired.
; In the heat set operation, the pledgets 88 and 90 acquire a circular
cross-sectional diameter expanding slightly from their initial
hexagonal shape. The amount of expansion can be adjusted relative to
the temperature and the length of time that the pledgets 88 and 90
remain in the apertures 72. The time can be adjusted depending upon
the diameter and speed of the heat set wheels 64 and 66. Besides
setting the cross-sectional diameter of each pledget, the heating
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operation also assists in sealing the trailing edge 92 of the cover
to the outer surface of the cover strip 20, see Figure 4. In
addition, the heat also bonds the cover strip 20 to the outer
circumference of the rolled absorbent ribbon 14.
The heat set wheels 64 and 66 are designed to rotate a
predetermined distance, for example about 180-, before the pledgets
88 and 90 are brought into alignment with a pair of nose
applicators 94 and 96. The nose applicators 94 and 96 are designed
to form a nose or rounded end on one end of each of the pledgets 88
and 90. Each nose applicators 94 and 96 is located adjacent to the
outside surface of one of the heat set wheels 64 and 66. ach nose
applicator 94 and 96 contains a moveable finger 98 and 100,
respectively. The fingers 98 and 100 are arranged to move inward
into coaxially alignment with the opening 72. Positioned on the
opposite or interior surface of each of the wheels 64 and 66 are a
pair of stops 102 and 104. The stops 102 and 104, which are depicted
as a pair of rollers in Figure 3, serve to prevent the pledgets 88
and 90 from being pushed out of the heat set wheels 64 and 66 when
the fingers 98 and 100 come in contact with one end of the pledgets
88 and 90. The fingers 98 and 100 are contoured into a sem;-
spherical shape such as to form a crown or round portion 106, see
Figure 7, onto the insertion end of each pledget. In the industry,
;,` this crown or rounded end is known as a Hnose" and the operation of
forming it is called "nosing".
It is advantageous to nose each of the pledgets 88 and 90 after
~ they have been heat set and shortly before they are to be withdrawn
.~ from the heat set wheels 64 and 66. The reason for the delay in
i performing the nosing operation is to make sure the pledgets 88
and 90 will not be exposed to a prolong period of heat wherein the
shape of the rounded nose could change.
~ After being nosed, the heat set wheels 62 and 64 are indexed to
;' a position wherein each of the pledgets 88 and 90 are brought intoalignment with a pair of ejectors 108 and 110. The ejector 108 and
~ 110 are positioned on the outside of the heat set wheels 62 and 64.~' 35 which are connected to a vacuum source. When the apertures 72, which
" house the pledgets 88 and 90 are brought into axial alignment with
the ejector 108 and 110, the pledgets 88 and 90 will be sucked out by
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- the vacuum. The pledgets 88 and 90 will be conveyed through feedlines 112 and 114, respectively, to a withdrawal string attachment
- device 116, see Figures 1 and 2.
At the withdrawal string attachment device 116, a pierce and
loop method is commonly employed wherein an awl or needle is used to
pierce an aperture 118 diagonally through each pledget. The
aperture 118, see Figure 7 can be formed approximate one end of the
pledget, usually about 1/8 to 1/2 inch from the trailing end. A
withdrawal string 120, normally constructed of cotton, rayon,
polyester, a blend of rayon and polyester, a polymer or other
suitable materials, is then threaded through the aperture 118. The
withdrawal string 118 is then looped upon itself to form a loop 122
- which secures it to the pledget. It is also common to tie a knot 124
into the free end of the withdrawal string 120. It should be noted
that there are many different ways of attaching the withdrawal
string 120 to a plsdget. Some of these methods are taught in U.S.
patents 2,553,000 at column 2, lines 39-48; 2,529,183; 4.302,174; and
4,318,407. The teachings of these patents are incorporated by
reference and made a part hereof. In addition, the withdrawal string
120 could be attached by wrapping it about the absorbent material 14
before the softwind 46 is compressed.
Referring to Figure 7, a finished tampon 126 is shown having an
insertion end 128 and a trailing end 130. The insertion end 128 is
the end which is first inserted into a woman's vagina and it is
located opposite to the trailing end 130.
Referring to Fig. 8, the finished tampon 126 is directed to a
packaging operation 132, see Fig. 1, wherein it is wrapped. The
wrapper can be a pouch made out of a polymer, such as polyethylene,
polypropylene, ethyl vinyl acetate, or other suitable material. The
wrapped pouches are then placed in a cardboard box or a plastic bag
for distribution to the ultimate consumer. Optionally, the finished
tampon 126 can be directed to an assembly operation 134, wherein it
is assembled into a tampon applicator 136, see Figure 8. The tampon
applicator 136 consists of a hollow outer tube 138 having an
insertion end 140 on which a plurality of petals 142 can be formed.
A pusher tube 144, having a smaller diameter than the outer tube 138,
is telescopically received within the outer tube 138 and can move
- 15 -
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relative thereto. The tampon 126 is positioned in the outer tube 138
with the withdrawal string 120 passing through the pusher tube 144
and extending outward therefrom. Various types of tampon applicators
are known in the art and they can be made from various materials
including cardboard, paper or plastic.
Referring to Figure 9, the tampon 126 can also have a stick 146
inserted into it's trailing end 130 to form a stick tampon 147. The
stick tampon 147 can be enclosed in a paper or plastic wrapper 148.
The wrapper 148 is sealed at 150 on one or both ends.
Referring to Figures 10 and 11, a cylinder or softwind 152 is
shown consisting of an absorbent ribbon 154 radially wound upon
itself and enclosed by a cover strip 156. The softwind 152 contains
an opening 158 formed therethrough and the initial width of the cover
strip 156 is shown being longer than the initial wid$h of the
absorbent ribbon 154. This size difference causes sleeves 160
and 162 to be formed on each end of the softwind 152. The
sleeves 160 and 162 can vary in size but enough cover material 156
should be present to permit the cover strip 156 to be tucked into
either end of the opening 158. In Figure 11, the softwind 152 is
shown having two tucked ends 164 and 166.
Referring to Figs. 12 - 15, the softwind 152 is compressed to
form an elongated pledget 168 having a hexagonal configuration. The
elongated pledget 168 is then cut into two single length pledgets 170
and 172, see Figure 13. Each pledget 170 and 172 has an untucked
end 174 and 176, respectively, which exhibits exposed absorbent
ribbon. Normally, the insertion end will be rounded to form a
nose 178 and a withdrawal string 120 can be attached to the trailing
end, as explained above, to provide a finished tampon 180, see
Figure 14. Optionally, the untucked end 174 can be rounded to form a
nose 182, see Figure 15.
Referring to Figures 16 - 18, an alternative embodiment is shown
wherein a softwind 186 is composed of a radially wound absorbent
ribbon 188 and a cover strip 190. The softwind 186 has a large
opening 192 formed therethrough. In this embodiment, the cover
strip 190 has the initial width which is less than the initial width
of the absorbent ribbon 188 and therefore a cylindrical cuff 194
and 196 is formed on each end of the softwind 186. The cylindrical ~ -
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cuffs 194 and 196 exhibits absorbent ribbon 188 which is uncovered.
The softwind 186 is then compressed into an elongated pledget 198,
see Figure 16. The elongated pledget 198 is then cut into two e~ual,
single length pledgets 200 and 202. The pledget 200 will contain a
cuffed first end 204 and an uncuffed trailing end 206. The first
end 204, which will preferably be the insertion end, will be
surrounded by the exposed ribbon 194. The other single length
- pledget 202 will contain a cuffed first end 208 and a trailing
end 210. The first end 208 will be surrounded by the exposed
absorbent ribbon 196.
Referring to Figure 19, the first end 204 of the pledget 200 is
rounded to form a nose 212. This nose 212 primarily contains exposed
absorbent ribbon 194. While either end of the pledget can be nosed,
it is now possible to form an uncovered nose on a cylindrically
covered tampon. A withdrawal string 120 can then be attached to the
pledget 200, as explained above, to form a finished tampon 214.
It should be noted that the configurations of the above-
; described tampons 126, 180, 184 and 214 are made possible by the use
of absorbent materials which contain enough integrity and structure
so that they can be inserted into a woman's vagina without being
partially or fully covered by a cover strip. `
While the invention has been described in conjunction withseveral specific embodiments, it is to be understood that many
alternatives, modifications, and variations will be apparent to those
skilled in the art in light of the aforegoing description.
Accordingly, this invention is intended to embrace all such
alternatives, modifications and variations which fall within the
`l spirit and scope of the appended claims.
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